Professional Documents
Culture Documents
1.0 SCOPE
3.0 GENERAL
4.1 Raw material used for making boiler drums shall meet
the requirements of SA 299 or SA 515 Gr.70 as specified
in drawing. The plates shall meet the requirements
given under TDC NO. 0:201 (latest on date of PO) for SA
299 and TDC NO. 0:202/00 (latest on date of PO) for SA
515 Gr.70 material. The details of sources from which
plates are procured, must be provided to BHEL well in
advance.
% Elongation E = T * 100
D + T
6.3 The dished end lay out is to the checked for centre-
line, height, location of man hole opening and other
dimensions as per drawings. The man hole opening and
seating area shall be machined to dimensions shown in
the drawing.
6.5 The man hole cut out shall be tested for tensile
strength and micro structure for ensuring conformance
to normalised properties, for each dished end per
thickness/melt/heat treatment batch and the values
shall be reported in TC.
7.0 WELDING
7.7 Before matching the second dished end with the shell,
both the man hole doors shall be put inside. The man
hole door shall be machined to size as per drawing from
normalised plates only.
8.1 The bow in the drum shall not exceed 1 mm per metre
length limited to a maximum of 8 mm.
9.1.1 All the butt weld joints shall be tested by 100% MPI
and 100% Radiography. Radiography reports shall be
furnished to BHEL.
9.1.2 All weld repairs shall be carried out according to
qualified procedures and shall undergo inspection
requirements as that of the main seam. All repairs
shall be recorded with dimensions of the groove made
for repair and shall be furnished to BHEL.
10.1 After welding and NDE clearance of all the seams, the
drum along with the test plates shall be stress re-
lieved in a furnace at 600-620 oC/30 minutes soaking/
Furnace cool upto 400 oC followed by air cooling. The
ROH/ROC shall not exceed 55 oC per hour. Thermocouples
are to be attached for measuring the temperature of
drum at equal intervals. Thermocouples are to be at-
tached to the test plate also. Location of the thermo-
couple must be indicated in a neat sketch.
10.2 After SR, each test plate shall be cut into two
halves. One half of the test plates shall be addition-
ally stress relieved at 600-620 oC/1 hour per inch of
shell thickness soaking/Furnace cool upto 400 oC fol-
lowed by air cooling. The ROH/ROC shall not exceed 55
oC per hour. The other half of the test plates (without
this SR) shall be sent to BHEL along with the drum. The
defect free length shall be at least 600 mm in each
test plate supplied to BHEL.
14.0 STAMPING
Product: CARBON STEEL FORGINGS TO SPECIFICATION SA 105 FOR USE IN BOILER DRUM NOZZLES
Document No.: TDC:0:401 Rev. No.: 01 Effective date: 25.02.04 Page 1 of 4
Records of Revision:
Rev 01 : In clause 5.0 for mechanical testing requirement for high temp tensile test deleted in line with IBR.
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1.0 SCOPE
2.3 Forging_practice
2.3.4.2 In the open die process, forgings made from hot rolled
billets shall be forged to diameter at least 76 mm
(3 inches) less than the starting size of the billet.
BHEL, Tiruchirappalli – 620014. Quality Assurance Technical Delivery Conditions
Product: CARBON STEEL FORGINGS TO SPECIFICATION SA 105 FOR USE IN BOILER DRUM NOZZLES
Document No.: TDC:0:401 Rev. No.: 01 Effective date: 25.02.04 Page 2 of 4
5.2 Macro_etching
5.2.1 A macro etch sample shall be taken from one end of the
forging of each size and each forging practice. A cross
section shall be polished and etched to develop flow
lines. Forgings which display a pattern of flow lines
that intersect both inside and outside are not acceptable
(See figure - 1 below).
BHEL, Tiruchirappalli – 620014. Quality Assurance Technical Delivery Conditions
Product: CARBON STEEL FORGINGS TO SPECIFICATION SA 105 FOR USE IN BOILER DRUM NOZZLES
Document No.: TDC:0:401 Rev. No.: 01 Effective date: 25.02.04 Page 3 of 4
Figure-1
8.0 REPAIR
Product: CARBON STEEL FORGINGS TO SPECIFICATION SA 105 FOR USE IN BOILER DRUM NOZZLES
Document No.: TDC:0:401 Rev. No.: 01 Effective date: 25.02.04 Page 4 of 4
11.1 BHEL reserves the right to carry out audit checks for
chemistry, heat treated condition, mechanical testing and
NDT on forgings at their discretion.
QUALITY ASSURANCE
06 19.05.2009
K.Mohan S.Selvarajan U.Revisankaran
RECORD OF REVISIONS
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Rev. No. Clause No. Details of Revision
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00/15.07.96 --- This procedure has been made from the document
PR:QE:015/03
04/ 31.03.06 Clauses 2.1 to 2.10 Re-arranged, modified and re-numbered as 2.1 to 2.8.
Clauses 3.3, 3.4, 4.1 Modified for clarity.
Annexure Deleted.
05/ 17.03.09 1.2 Revised. Basis of Hydro test pressure for ASME Sec.VIII.D2
vessels is changed based on the revision of ASME
Sec.VIII.D2
1.0 SCOPE
1.1 This procedure covers the requirements of hydrostatic testing of pressure parts in boilers,
pressure vessels, heat exchangers, studded pipes etc. The specific requirements, if any,
mentioned in the respective quality plans are also to be followed during the test.
1.2 Hydrostatic test shall be conducted at the minimum test pressure specified in the drawing. The
basis for calculating test pressure is as follows:
a) For parts of IBR & ASME Sec. I : 1.5 times the MAWP
b) For parts of ASME Sec. VIII Div.1 : 1.3 times the MAWP x SR
where MAWP = Maximum allowable working pressure and SR is the lowest ratio (for the
materials of which the vessel is constructed) of the stress value S for the test
temperature on the vessel to the stress value S for the design temperature.
c) For parts of ASME Sec. VIII Div. 2 : Greater of 1.43 x MAWP (or) 1.25 x MAWP x (ST/S)
where MAWP = Maximum allowable working pressure and ST’ is the allowable stress at
Test temeperature and ‘S’ is the allowable stress at Design temperature and the ratio
(ST/S) is the lowest ratio for the pressure boundary materials, excluding bolting
materials, of which the vessel is constructed
2.1 Before hydrostatic test, the components shall be complete with regard to welding, NDE, PWHT
etc. as envisaged in the drawing and QP.
2.2 All the openings shall be closed with proper dummy welding or suitable mechanical fixtures.
2.4 An indicating guage shall be connected to the pressure part such that it is visible to the operator
controlling the pressure applied. The pressure indicating gauges selected shall have dials
graduated over a range of double the intended maximum test pressure; but in no case shall the
range be less than 1.5 times the test pressure nor more than 4 times the intended test pressure.
The spacing between graduations shall be such that the inspector and the operator controlling
the test shall be able to determine when the required test pressure has been applied. The
pressure guages shall have valid calibration.
2.5 For drums, headers and vessels, two pressure guages shall be used. One guage shall be kept
on the top location of the part under test and the other one at any other convenient location.
However, for tubular parts where pressure head is very low, the guage can be kept in the
pressure line itself.
2.6 Vents shall be provided at all high points of the component / assembly in the position in which it
is to be tested to purge possible air pockets while the components is being water filled.
2.7 The pressurising system shall have suitable valve connections such that the part under testing is
isolated during the test.
2.8 Potable water shall be used for the test, unless specified otherwise. The temperature of water
shall be not less than 20 deg. C and not more than 50 deg. C during the test.
SIP:PP:04/ 06 Page 4 of 4
2.8.1 For ASME Sec. VIII Div. 1 & 2 applications, it is recommended that the vessel metal temperature
during testing is maintained at least 17 deg. C above the minimum design metal temperature
(MDMT), but need not be more than 50 deg. C. In all cases, if the test temperature exceeds 50
deg. C, inspection of the vessel shall be delayed until the temperature is reduced to 50 deg. C or
less.
3.1 The hydrostaic test shall be conducted in the presence of Authourised inspector / inspecting
officer, wherever applicable.
3.2 After complete venting, vents shall be closed. Careful examination shall be done for possible
leakages especially in dummy blanks before pressurising. The pressure shall be raised
gradually. In case of boiler parts, actual pressure may exceed the test pressure by note more
than 6% provided no part of the boiler shall be subjected to a general membrane stress greater
than 90% of its yield strength (0.2% offset) at test temperature.
3.3 The test pressure shall be maintained for 30 minutes (5 minutes for tubular products in boilers)
minimum and then reduced to the pressure as follows.
b) For ASME Sec.VIII Div.1 - Not less than the test pressure divided by 1.3
c) For ASME Sec.VIII Div.2 - Not less than the test pressure divided by 1.43
3.4 This pressure shall be maintained for a sufficient period to permit complete examination by the
inspecting authority.
3.5 A close visual examination shall be carried out for leaks / sweats in welds at the pressure
indicated as above. No leak / sweating is permitted. When there is an appreciable pressure drop
without any gross leakages, the joints in the pump flanges, valve gasket and dummies shall be
checked for leakages. After arresting them, the test shall continue.
3.6 Where leaks are noticed, it shall be recorded. After draining the water completely, the repair
shall be done with the approval of the inspecting officer. Post weld Heat treatment, if required for
repair, shall be done before retest.
3.7 When repairs are made, the part shall again be subjected to the hydrostatic test as in the regular
way.
3.8 After successful hydrostatic test, the component shall be completely drained and dried where
necessary.
4.0 STAMPING
4.1 After successful hydrostatic testing, the test parameters shall be stamped as detailed in the
Quality Plan / Drawing for stamped parts / assemblies such as vessels, heat exchangers, drums,
headers and pipings of dia. 127 mm & above. The details shall be stamped on a name plate /
component.
5.0 DOCUMENTATION
5.1 A facsimile of the stamping details shall be taken on a tracing and filed.
5.2 A hydrostatic test report shall be prepared, duly signed by the inspection agency and filed.
@@@@@
BHEL, Tiruchirappalli - 620014. Quality Assurance Standard Inspection Procedure
Product: QUALITY ASSURANCE DIAMETER, CIRCULARITY & PROFILE REQUIREMENTS (BOILER
DRUMS)
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Rev. No. Clause No. Details of Revision Remarks
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1 .0 SCOPE
This procedure details out the quality requirements for diameter, circularity and
profile for shells and dished ends for boiler drums.
2.0 REFERENCE DOCUMENTS
IBR, ASME Section I.
3.0 QUALITY REQUIREMENTS
SHELLS
Diameter
Circumference measurements shall be performed at intervals of approximately
1 metre over the full length, on the outside of the vessel shell. From these
measurements, the average outside diameter shall be calculated. The outer
diameter shall not depart from the given theoretical outside diameter by more than
+ 1%.
Circularity
The difference between the maximum and minimum inside diameters measured at
any cross section of the shell shall not exceed 1% of the nominal(average) inter-
nal diameter at the cross section under consideration.
The diameters may be measured on the outside or inside of the vessel. If meas-
ured on the outside, the diameters shall be corrected for the plate thickness at the
cross section under consideration.
When the shell is made of plates of unequal thicknesses, the measurements shall
be corrected for the plate thicknesses, as they may apply, to determine the dia-
meters at the middle line of the plate thickness.
When the cross section passes through an opening or within 1 ID of the opening
measured from the center of the opening, the permissible difference in inside
diameters may be increased by 2% of the ID of the opening.
In order to meet the circularity requirements, the shell may be rerolled, reformed
and heat treated subsequently, if necessary. If this occurs, it shall be followed by
NDE (MPI & RT/UT) on the weld seams.
Profile
Any departure of profile measured on the outside of the shell with a profile gauge
of the designed form of the exterior of the shell, having length equal to a quarter
of the nominal internal diameter shall not exceed the percentage given below.
Flats at the welded seams shall not be permitted and any local departure from
circularity shall be gradual.
Nominal ID of drum Profile departure in
Percentage of nominal ID
Upto and including } 0.375
914 mm }
Document No.: SIP:PP:05 Rev.No.: 00 Page: 2
Over 914 upto and } 0.350
including 1143 mm }
Over 1143 mm 0.300
DISHED ENDS
Diameter
The outer circumference of the dished end shall be measured at the skirt portion
and the outer diameter shall be calculated. The outer diameter shall not depart
from the given theoretical outside diameter by more than + 1%, however this
deviation shall not affect the thickness requirement during machining.
Circularity
The skirts of dished ends shall be sufficiently true to round so that the difference
between the maximum and minimum diameters shall not exceed 1% of the
nominal (average) diameter. However, this out of circularity shall not affect the
thickness requirements during machining.
Profile (For ASME Section I applications only)
The inner surface of the Ellipsoidal dished ends shall not deviate outside of the
specified shape by more than 1.25% of the nominal inside diameter of the dished
end (ID at the skirt portion). Departure inside of the specified shape shall not be
permitted.
The deviation measurements shall be taken on the surface of the base metal and
not on welds, using a profile gauge having length not less than a quarter of the
nominal ID of the dished end.
4.0 DOCUMENTATION
The diameter, circularity and profile measurements shall be recorded in checklist,
log or history card.
Columns 35 - 1xx
Columns 39- 1 xx
NOTE The above-mentioned changes will be incorporated in the relevant QWI during the
next revision of the document.
RECORD OF REVISIONS
1.0 SCOPE
1.1 This procedure covers the requirements of Surface preparation and application of Primer and
Finish paints for components of FB, IPP, Valves and Spares based on environmental and service
conditions.
1.2 Special Contractual requirements, if any, will be indicated in a) the respective Drawings
(when customer approval is require d) b) through a separate Contract Specific Document (
with customer approval wherever called for) . The Contract Specific Document will be
initiated by the concerned Engineering/ Commercial/Contracts/ Marketing group and further
details filled in by Plant Laboratory). The linkage will be provided in the CQR issued by QA.
2.0 GENERAL
2.1 This procedure specifies the painting requirements to a) provide adequate surface protection of
components under good storage conditions at Site b) temporary protection for components
coming inside the boiler in flue gas path till they are erected inside the boiler and c) protection for
a reasonable time till completion of erection for components continuously exposed to
atmospheric environment.
2.2 However, sites shall assess the need and carry out cosmetic re-preservation as required when
components are received at site and subsequently, at a predetermined periodicity based on site
storage conditions..
2.3 For bought-out items, the painting scheme shall be as specified in Engineering Drawing /
Specification. Wherever it is not specified, it shall be as per the painting scheme of the
applicable PGMA in this document.
2.4 In case of any non-clarity / missing PGMAs in painting scheme, the concerned Engineering
Group may be contacted for clarification.
3.1 The surface preparation, primer coat and finish coat requirements for various painting schemes
are given in Annexures I to IV
3.2 The Paints envisaged in this document are coded as Pa XX and the details of the paint
specification are given in Annexure - I (b).
4.0 SURFACE PREPARATION
4.1 Surfaces of components shall be thoroughly cleaned before the application of primer paint
and shall be free from grease, oil, dust, rust, weld slag, spatters etc..
4.2 Abrasive blast cleaning to SSPC-SP6 (Sa 2)grade shall be done to prepare the surface of hot
worked pipes prior to application of primer.
5.3 Ready mixed paints shall be used as supplied by the supplier without any addition of thinner
unless otherwise specified. Two pack systems are to be used as per supplier’s instructions.
5.4 Wherever Second coat or Finish coat is to be applied in succession, 12 hours minimum drying
time shall be provided between each coat for single pack paints. For two pack system refer paint
supplier’s catalogue.
5.5 No painting is required in case of Stainless Steel, Aluminum and Galvanized components,
unless otherwise specified in contracts.
5.6 For all machined components, rust preventive fluids shall be applied .
5.7 All weld edge preparations for site welding shall be applied with one coat of Weldable
primer. For small components having weld ends on both sides, full surface can be painted with
weldable primer.
5.8 Part processed items meant for shop assembly shall be painted at sub-contractors works with
primer / special paints (when called for in the painting scheme) based on the scope of the
indent/Purchase Order. Further paint touchup / Coating shall be given appropriately during
assembly.
5.9 All threaded components of spring assemblies and turn buckles shall be galvanized and
achromatized to 15 microns minimum thickness
5.10 For items meant for Spares and subcontracting where no further processing is involved, , the
painting scheme selected shall be the same as that of similar product configuration / description
and not with respect to PGMA. All running meter items for spares one coat of Red Oxide primer
is sufficient.
5.11 Assemblies consisting of machined components and special equipments shall not be shot
blasted wherever it may affect the system. In such cases power tool cleaning may be
adopted for the localized areas only.
5.12 In components (For example: Expansion Joints), wherever plates / sheets of thickness less than or
equal to 5mm is used, power tool or Sand /emery paper cleaning can be adopted with painting
scheme 3, or alternate scheme as specified in the contract painting scheme.
5.13 Wherever inside surfaces of components need protection till erection (for example inside surfaces
of ducts and dampers), two coats of primer (Pa 8) are to be applied.
6.1 For internal protection of Pipes , tubes, headers and other pressure parts , VCI pellets shall be
put ( after sponge testing / draining and /or drying ) and subsequently end capped.
6.2 The dosage of Volatile Corrosion Inhibitor (VCI) pellets shall be approximately 100 grams/ m3
For tubes typically 4 -5 tablets per end are to be put.
6.3 For C & I items the dosage of self indicating Silica gel (color less) shall be 250 grams per
Cubic meter. (about 2 to 3 bags weighing approximately 100 grams each) .
6.4 VCI pellets shall not be used for stainless steel components and its composite assemblies.
Wherever required, paints and rust preventive protection can be removed either by using the
following commercial solvents or by flame cleaning/ blasting.
To get a profile of 25-50 microns, the following sand , grit or shot sizes are to be used for
getting optimum results.
Paint
Specification PAINT DESCRIPTION
code
Pa 1 Red oxide Zinc phosphate primer (Alkyd Base) to IS 12744 by brush
/spray
Pa 2 Synthetic Enamel long oil Alkyd to IS 2932 (latest)
Pa 3 High Build Chlorinated Rubber based Zinc Phosphate Primer
% Volume Solids = 40 (min), DFT= 50µm / Coat (min)
Pa 4 Chlorinated Rubber based Finish Paint
% Volume Solids = 30 (min), DFT= 30µm / Coat (min)
Pa 5 Non drying type rust preventive fluid to IS 1154 (latest)
NOTES
i. Machined surfaces and threads are to be applied with a coating of Rust Preventive Oil .
ii. All shade numbers are as per IS 5. Unless otherwise specified Color/Shade shall be Smoke
gray Shade No. 692 of IS5.
SIP:PP:22/03 PAGE : 12 of 14
ANNEXURE IV –
PAINTING REQUIREMENTS FOR FBC & HRSG
NOTES:
1. Rust Preventive Coating to be applied on HSFG Bolt threads and other threaded components.
2. Machined surfaces are to be applied with a coating of Rust Preventive oil.
3. All shade numbers are as per IS 5. Unless otherwise specified Color/Shade shall be Smoke gray
Shade No. 692 of IS5.
BHARAT HEAVY ELECTRICALS LIMITED
TIRUCHIRAPPALLI - 620 014
QUALITY ASSURANCE DEPARTMENT
AMENDMENT TO QUALITY WORK INSTRUCTIONS (QWI)
3.5.4 All components shall be loaded in raised platforms to avoid flame impingement during heat For
treatment in gas furnaces. The components shall be adequately supported to minimize better
distortion. Ensure test plate loading if applicable. clarity
3.5.13
For interruptions during heat treatment, the following action has to be taken depending on the
stage of occurrence:
Type of Heat treatment Stage of interruption Action
3.5.14 If any thermocouple fails during furnace heat treatment, it shall be ensured that at least
two thermo couples (covering the entire equipment / batch) reasonably are functioning
within 4.5 metre distance. In case of local heat treatment, at least one thermocouple
monitoring the temperature of the weld zone shall be functioning. One stand by
thermocouple may be provided in the weld zone, which can be connected to the recorder
in case the already connected thermocouple fails. Otherwise, PWHT is to be
discontinued and restarted.
3.10.1 Unless otherwise specified, the tolerances for untoleranced dimensions shall be as per
Drawing No. TP:023:0299 (latest)
NOTE The above-mentioned changes will be incorporated in the QWI during the next revision of the document.
RECORD OF REVISIONS
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Rev. Date Clause Details of revision
No. No.
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00 01/04/93 This document consolidates all the general requirements
and technical disciplines covered in the various QCPs.
3.3.3.2, Added
3.3.10
Annexure I Modified
1.0 SCOPE
1.1 This procedure details out various disciplines to be followed during fabrication of
pressure parts other than tubular products with respect to:
1.2 The specific product quality requirements are detailed in relevant Std. Quality
Plan (SQP)/Inspn. & Test Procedure (SIP)
2.1.1 During incoming inspection, the raw materials, welding consumables and sub deliveries
are to be verified for correctness through test certificates (TC) as per relevant Technical
delivery condition (TDC) / Material Specification/Purchase specification. This is applicable
for Customer supplied materials also. Components received from subcontracting works
are to be verified for correctness through Inspn./Dimension report.
2.1.2 Issue of materials shall be as per the MIV/MRS/CRS and freedom from visual damages
like pitting, dents, laminations, scales, warpages etc. shall be ensured.
2.1.3 When in raw matls, defects are noticed, the same shall be confirmed by using appropriate
NDE techniques and corrected, in consultation with QC.
2.1.5 ATTEST/PRODUCT ATTEST items, indicated as "A/P" in drawings, are traceable to the
test certificates (TC) and identified as below. These items are issued with Attestation
Form correlating the TCs and product through Work Order.
2.1.6 CERTIFIED items, indicated as "C" in drawings, are traceable to Specification / Grade
only and identified by stamping/ engraving/ stenciling/ color coding/ marking.
2.1.7 Raw materials not covered by the above shall be identified by its W.O.No/ material code/
specification/ grade by painting or stenciling or engraving. All sub deliveries shall be
identified by its material code by painting or through tags / name plates.
BHEL QCP:001/05 Page 4 of 16
2.1.8 In case of marking, cutting or machining, the transfer of material identification shall be
certified by QC. In case of tubes, the color code shall be transferred.
2.1.9 For stock raw materials, which are upgraded for special contract requirements, QC shall
ensure that the respective TCs and laboratory reports satisfy specification/Contract,
TDC/CQP as applicable and identified with W.O.No.
2.1.10 Unidentified materials if found in processing shall be verified for specification and
H.T.condition through appropriate checks and shall be upgraded (wherever required) for
relevant application.
3.0 PROCESS CONTROL [Refer Annexure I for P number grouping of materials &
Annexure II for tolerance drawings].
3.1 FABRICATION
3.1.2 Whenever marking operation is carried during shell plate layout, openings on shells,
dished ends or pipes, hole locations on baffles/ girth flanges/ tube sheets,
attachments locations etc. the marking correctness shall be ensured as per relevant
drawing. The marking shall be identified with punch marks. Wherever required the
allowance for cutting/ machining shall be provided.
3.1.3 Before removal of any identification marks during cutting / machining they shall be
transferred on adjacent area and certified by QC. All marking inspection shall be
performed by QC prior to further operation. The material Specn./Grade/Melt
No./Attestation No., as applicable, are to be transferred on balance raw materials for
future use.
3.1.4 Reference line mark shall be ensured at a distance of about 100mm from the free
ends. For pipes meant for bending and attachment welding, center line marking shall be
done.
3.1.5 Cutting may be done by shearing, saw cutting or gas cutting. Stainless steel shall be
plasma cut or sheared. Where shearing is for thickness > 25 mm., the cut edges shall
be ground. Only saw cutting shall be used for X20 and P91 materials.
3.1.6 During gas cutting and thermal gouging, proper preheating shall be ensured. The
requirements of preheating for gas cutting / gouging is as follows.
3.1.7 The thermal cut edges shall be ground to be free from surface irregularities, scales
and burrs,chips etc. The ends prepared for welding shall conform to the relevant
drawing. Unless and other wise specified in SQP/CQP all bevels / edges, which are gas
cut and are to be welded to pressure parts, shall be ground to 1 to 2 mm for removal
of HAZ and checked by LPI/MPI.
BHEL QCP:001/05 Page 5 of 16
3.2 FORMING
3.2.1 General.
3.2.1.1 Forming shall be done using proper toolings free from high spots and damages. The
process/tooling shall have been qualified by a first off trial and the records shall be
verified for compliance before production, as applicable.
3.2.1.3 The prebend profile shall be ensured for correctness before forming shells to final radius.
3.2.1.4 The profile shall be checked using a template of forming radius and chord length at
least equal to 1/4 ID. Surface waviness shall be suitably sized. Variations of the profile
shall not be abrupt but shall merge gradually in the specified shape.
3.2.1.5 Surface depression in formed areas shall be merged gradually into the base
material surface to 1:4 taper. Minimum thickness after forming shall be verified &
ensured.
3.2.1.6 Carbon Steel Plates shall be normalized before cold forming if the plates are received
in "as rolled condition".
3.2.2.1 Fiber Elongation (FE)in % = 50t/R for single radius and 75t/R for multiple radius, Where
t = thickness, R = Mean radius
3.2.2.2 Cold Forming/Sizing can be done for Material Groups P1 to P5 without inter stage Heat
Treatment under the following conditions.
I. For thickness 50 mm and below, if outer fiber elongation does not exceed 5 %.
II. For thickness above 50 mm and up to 100 mm, if outer fiber elongation does not
exceed 3.5 %.
III. For thickness above 100 mm and up to 150 mm if outer fiber elongation does not
exceed 3 %.
IV. For thickness above 150 mm cold forming is not recommended.
3.2.2.3 When the above conditions are not met, forming in 2 stages is required. Initial forming
shall be done to a radius which satisfies above conditions. Then an inter stage
heat treatment is to be carried out as per Clause 3.5.8 before forming to finishing radius.
3.2.2.4 When cold rerolling of shells is to be done after welding, the following shall be ensured.
b. Interstage Heat Treatment of Shells after welding and before rerolling is required as
below.
3.2.2.5 During cold forming of stainless steel plates suitable nonmetallic pads shall be used
to avoid direct contact with ferritic materials. Cold forming of austenitic stainless steel
material (P8) can be done without further heat treatment if the outer fibre elongation does
not exceed 10%.
3.2.2.6 Heat treatment after cold forming of P8 steels shall be as per relevant SQP/CQP.
3.2.3.1 During hot forming the material shall be heated all round uniformly to the specified
temperature.
3.2.3.2 After hot forming and prior to cold sizing / weld fit up of material groups P3,P4,P5, a
tempering operation shall be carried out . The temperatures shall be as per Cl:3.5.8
unless otherwise stated.
3.2.3.3 Post form heat treatment can be combined with PWHT of the product/component as
per Clause 3.5.8 except for P5 Formed fittings, P5 Plate formed pipes.
3.2.3.4 After hot forming, Heat Treatment shall be carried when required as per relevant
SQP/CQP . The temperature shall be as per relevant SQP/CQP.
3.2.3.5 P8 materials when Hot Formed require Solution Annealing (SA) as detailed out in the
relevant SQP/CQP.
3.2.4.3 Soaking during heating / Post forming heat treatment shall be as per below guide lines.
Hot working/Normalizing ¦ 1/2 hour per inch of "t" (15 minutes minimum)
SR/Tempering ¦ CS - 1 hour per inch of "t" for “t” upto 2 inches with an
additional 15 minutes for every inch above 2 inches
(15 minutes minimum).
AS - 1 hour per inch of "t"
(P3 & P4) - 30 minutes min.
(P5A) - 60 minutes min. except for P5A pipes of
OD <= 127mm and t <= 13mm, which require
only 30 minutes)
(P5B) - 120 minutes min.
Solution Annealing ¦ 1 hour per inch of "t" (15 minutes minimum)
where " t " is nominal thickness for plates, pipes and diameter for bar stock.
3.2.4.3.2 In case of pipe bends / fittings, thickness “ T “ for determining soaking time shall be
calculated as
T = t * (2R - r) / (2R – 2r) where “ R “ is the radius of the bend and “ r “ is the
mean radius of the pipe.
3.2.5 The temperatures are only indicative. The actual temperature shall be as per material Mill
TC wherever Simulation Heat Treatment is a requirement.
3.2.6 All heat treatment shall be applied only after the component temperature falls below
200 deg. C (below 100 deg. C for P91). Temperature of the furnace during loading shall
be below 300 deg. C.
3.2.7 Any scales due to hot forming shall be removed by suitable blasting in case of ferritic steel
and pickling/passivation in case stainless steel.
3.3 WELDING
3.3.1 Fit-up of the weld joints including Tube to tube sheet joints shall be ensured as per
drawing. All run out pieces, bridge on pieces and temporary attachments shall be
identified and welded with necessary preheat and matching electrodes.
3.3.1.1 The material for temporary attachments shall be ferritic for ferritic materials and
stainless for stainless steel.
3.3.2 Tack welds used to secure alignment shall either be removed completely when they
have served their purpose or their stopping and starting ends ground or dressed by
other means suitably so that they may be incorporated into the final weld.
3.3.2.1 Tack welds shall be done to a sufficient length (25 mm minimum) and width using
qualified procedure and personnel . Tack welds found defective during visual
examination shall be removed.
3.3.3 For single side welding, the maximum misalignment for butt welds shall not exceed
1.6mm. However, where backing rings are used, the gap between backing ring and
surface shall not exceed 0.4mm
3.3.3.1 Tolerance for alignment (surface mismatch) of butt welds shall be as per table below
unless requirements are otherwise specified in respective Standard/Contract Quality
Plans.
3.3.3.2 If plate edges of unequal thickness are abutted and the surface offset exceeds the limits
mentioned above on either side, the thicker plate shall be thinned down to a smooth taper
of 1:4 minimum over the width of the weld.
BHEL QCP:001/05 Page 8 of 16
3.3.4 Weld and adjacent base material surface approximately 15 mm on either side of weld
shall be thoroughly cleaned and ensured free from oil, grease, rust, scales etc. For tube to
tube sheet joints cleanliness of tube and tube sheet holes shall be ensured before fit up.
3.3.5 Preheat/Inter pass requirements for welding shall be as per the WPS and controls shall be
exercised as detailed below:
3.3.5.1 Preheating must be applied using gas burner or induction / resistance heating method
before starting each cycle of welding as specified in WPS. Preheat temperature,
subsequent extended preheat/inter pass temp. shall be maintained and verified
throughout welding using thermal chalks (temperature indicating crayons)/
thermocouples. The preheat shall be applied for a width of 75 mm or 1.5 times the base
metal thickness, whichever is more, around the point of welding (not less than 25 mm in
case of tack welding) in all directions.
3.3.6 Welding shall be performed with qualified procedures and qualified personnel. Welding
procedures are qualified to ASME Sec. IX and personnel to IBR/ASME Sec.IX, unless
specified otherwise.
3.3.7 Ensure correctness of welding consumables before use including baking and drying.
Where specified, the batch traceability shall be maintained through records.
3.3.8 Wherever post heating is specified in WPS, the preheat temperature shall continue after
welding till attaining the post heat temperature and maintained for the required time and
cooled slowly.
3.3.9 In Headers and Piping products, the distance between any two pipe butt joints shall be
greater than one diameter and shall not be less than 500 mm. For tubes, the minimum
distance between butt joints shall be 150 mm except for inserts which shall be as per
drawing.
3.3.10 In case of interruptions in welding, the minimum preheat temperature shall be maintained
until any required PWHT is performed on P3, P4, P5A, P5B and P6 materials except when
all of the following conditions are satisfied.
3.4.1.1 After completion of welding, visual inspection shall be done as per SIP:PP:02 (latest),
unless specified otherwise in the relevant SQP/CQP.
3.4.1.2 Where parts of different thickness are welded, the change in thickness shall be made
gradual, either by grinding or machining to a 1:4 taper.
3.4.1.3 Stray arcs shall be avoided. Arc spots, if any, shall be ground and checked by
LPI/MPI. Ensure thickness requirements in such cases.
BHEL QCP:001/05 Page 9 of 16
3.4.2.1 The extent and type of NDE are specified in the respective SQP/CQP.
3.4.2.2 NDE shall be performed using qualified procedures and personnel only. NDE techniques
are based on ASME Sec. V unless specified otherwise. The acceptance norms shall be
based on the relevant code of construction, built into the respective NDE procedures and
approved by the statutory authorities, as required.
3.4.2.3 The Welder No., radiography No. and reference axis marks shall be punched in case
of radiography joints of size above 108 mm. In case of other welds suitable records can
be maintained correlating the weld joint.
3.4.2.4 In drums and alloy steel headers, when tube holes are envisaged on weld seams
(longitudinal and circumferential), such welds shall be radiographed and stress relieved
prior to tube hole drilling.
3.4.3 Repairs
3.4.3.1 Defects noticed shall be removed by air arc gouging, drilling, machining or grinding with
suitable bevel for welding. When defects are air arc gouged preheat shall be applied as
required for gas cutting of material and the cavity shall be ground to remove black
spots. The area shall be free of any irregularities that might trap slag during welding.
Gouging is not permitted for P91 and X20 materials.
3.4.3.2 MPI/LPI shall be conducted on the cavity to ensure complete removal of defects, such as
cracks, ICP and lack of fusion. For other defects such as slag, pores etc., a thorough
visual inspection is necessary before repair welding.
3.4.3.3 All repair welding shall be using qualified WPS and qualified welders.
3.4.3.4 Defects in the completed test plates shall not be repaired. Defect free portion can be
used for testing.
3.4.3.5 The repair welds shall be subjected to the same NDE as per the original weld.
3.4.3.6 After all welding, NDE and successful weld repairs, the welds shall be visually
inspected for completeness and cleared for heat treatment wherever applicable.
3.5.3 The thermocouples and recording instruments shall be calibrated and records
maintained. The furnace shall have been qualified for temperature distribution.
3.5.4 All materials shall be loaded in raised platforms to avoid flame impingement during heat
treatment in gas furnace. Ensure test plate loading if applicable.
3.5.5 Thermocouples shall be attached to the component as per the following guidelines:
a. Thermocouples shall be placed such that the entire component (including the
anticipated hottest and coldest zones) is covered.
b. The maximum distance between any two thermocouples shall not exceed 4.5 metres.
c. The temperature variation between any 4.5 metre distance shall be 100 deg. C maximum
for temperature above 400 deg. C during heating.
BHEL QCP:001/05 Page 10 of 16
3.5.6 Local heat treatment can be done either by Resistance heating or by Induction heating.
P91 and X20 components shall be locally heat treated using induction heating only.
3.5.6.1 When heat treating butt joints, width of the circumferential heating band on either side
of the weld must be at least 3 times the width of the widest part of the weld groove; but
not less than twice the thickness of the thicker part welded.
3.5.6.2 When heat treating nozzles and attachment welds, the width of the heating band on
either side of weld shall be 6 times the base material thickness beyond the welding to
be heat treated. The heating band shall extend axially around the entire vessel.
3.5.6.3 Width of the insulation band beyond the heating band shall be at least twice the total
width of the heating band.
3.5.6.4 A minimum of three thermocouples shall be placed such that at least one is on the
weldment / HAZ and the other two on the base material on either side of the weldment
within the heating band. Two Thermocouples are sufficient for Piping & Header items.
3.5.6.5 The winding arrangement shall be established to attain the required temperature. The
rate of heating shall be maintained minimum such that it stabilizes at the required
rate before reaching 400 deg C.
3.5.7 Unless otherwise specified in SQP/CQP, the following rules shall apply to establish
the governing thickness (T) for determining the soaking time for PWHT. Soaking time
is accounted as the time between the temperature crossing and leaving the minimum
recommended temperature.
3.5.7.1 For Butt welds, "T" shall be thickness of the weld. For bar stock "T" shall be the
diameter. For fillet welds, "T" shall be the throat thickness. If a fillet weld is used in
conjunction with a groove weld, "T" shall be the total of the depth of the groove plus
the fillet throat thickness.
3.5.7.2 For partial penetration branch welds, the thickness shall be the depth of the groove
prior to welding.
3.5.7.3 For repairs, the thickness shall be depth of the groove as prepared for repair welding.
3.5.7.4 For combination of different welds in a component, the higher governing thickness "T"
shall govern.
3.5.7.5 For IBR items having welded joint connecting parts of different thickness, the governing
thickness (T) for determining the soaking time for PWHT shall be the maximum
thickness of the part welded.
3.5.8 Guidelines for selecting soaking temperature for PWHT unless specified otherwise in
relevant WPS/SQP.
a)
b) Rate of heating / cooling for SR and rate of heating for tempering shall be as below
unless otherwise specified. Incase of SR, cooling shall be in furnace up to 400 deg. C
(350 deg. C for X20 and P91) and further in Air.
Thickness of Material Maximum Rate of Heating & Cooling above 400 deg. C
Up to 25mm 220°C/Hr
Over 25 - 50mm 110°C/Hr
Over 50 - 75mm 75°C/Hr
Over 75mm 55°C/Hr
3.5.9 Unless otherwise specified, in case of mixed loads of materials not covered under
simulation HT, the following heat treatment temperatures shall be followed. In such
cases, guidelines for soaking can be taken from Clause 3.5.10.
i) Where a component has a butt joint between P1 & P4, or P3 & P4, the cycle shall
be 630 - 670 deg. C (Minimum 650 Deg. C for ASME jobs).
ii) Where a component has a butt joint between P4 & P5A, the cycle shall be 680 -
720 deg. C.
iii) Where a component has a butt joint between P1 & P3, the cycle shall be 620-660
deg. C.
iv) Where a component has a butt joint between P5A & P5B, the cycle shall be 730-
760 deg. C.
v) For P1+P5A material combination, follow the WPS requirements.
The following jobs shall not be combined in the same cycle during PWHT.
3.5.10 For PWHT of materials not covered under simulation heat treatment, in case of
combination cycles mentioned above, calculate the minimum soaking time for individual
components as 2.5 minutes/mm of the thickness of weld/material whichever is
applicable. Soaking time selected for the cycle shall not exceed the limits given below:
3.5.11 After PWHT, the charts shall be correlated with the job and cleared by QC. The charts
shall contain the cycle No., date, recorder number, and WO & material details. The cycle
temperature, ROH,ROC & soaking time shall be calculated from the chart and entered in
the chart signed off by QC and statutory authorities as required.
3.5.12 Wherever specified, the test plate shall be tested and reports obtained to complete
the clearance of heat treatment operation.
BHEL QCP:001/05 Page 12 of 16
3.5.13 For interruptions during heat treatment, the following action has to be taken depending on
the stage of occurrence:
3.5.14 If any thermocouple fails during furnace heat treatment, it shall be ensured that at least two
thermo couples (covering the entire equipment / batch) reasonably are functioning. In
case of local heat treatment, at least one thermocouple monitoring the temperature of the
weld zone shall be functioning. One stand by thermocouple may be provided in the weld
zone, which can be connected to the recorder in case the already connected thermocouple
fails. Otherwise, PWHT is to be discontinued and restarted.
3.6.1 When hot correction for bow, distortion, alignment etc. is required, flame heating may be
adopted, limiting the maximum temperature as below.
For C.S & T91, the temperatures shall not exceed the above values. For others, if the
temperature exceeds the above limits, the items shall be subsequently stress relieved.
The metal temperature shall be checked using thermal chalks or other suitable means.
Flame heating shall be avoided on headers, but correction can be done by mechanical
means/induction heating limited to the temperatures specified above.
3.6.2 If the points of contact during mechanical correction are exactly on the butt joints, such butt
joints shall be tested by RT/UT after correction.
3.7.1 Before expansion of Tube to tube sheet joints, ensure thorough cleanliness of the tube
ends for a distance equal to tube sheet thickness plus 30 mm.
3.7.2 Suitable lubricants shall be used for expansion. The expansion toolings like mandrel,
rollers etc. shall be examined periodically to be free from damage.
3.7.3 Expansion shall be done using the qualified torque for the required length.
BHEL QCP:001/05 Page 13 of 16
3.7.4 QC/Shop shall ensure correctness of expansion in each shift periodically. In the case
of expansion to full thickness of Tube sheet it shall be ensured that the expansion
shall terminate 3 mm from the back face of the Tube sheet.
3.7.5 The expanded area and the tube sheet face shall be cleaned thoroughly.
3.8.2 Wherever air leak test is called for, the test medium shall be air or Nitrogen. The test
pressure shall be raised gradually . Test parameters shall be as per SQP/Drawing.
3.8.3 Wherever hydrostatic test is specified, the same shall be performed in accordance with
SIP:PP:04 (latest) or relevant SQP/Drawing.
3.9 MACHINING
3.9.1 The work center for finish machining shall be identified on the OPS based on the process
capability of the machine or Machine accuracy established to suit the tolerances. All
cutting tools shall have been ensured for correctness before use.
3.9.2 Software used in case of CNC/NC machines shall have been validated through trials or
inspection of similar components produced and accepted.
3.9.3 Ensure verticality and parallelity of the jobs on the machine by using the reference
markings or dialing the surfaces after clamping the job and periodically during machining.
3.9.4 After machining the surfaces shall be suitably deburred and cleaned. After removing
from the machine it shall be properly stored.
3.9.5 During drilling or tapping, the removal of chips shall be done periodically to prevent
clogging of chips inside the hole. For deep drilling ensure that run out, drill travel are
verified in free condition and ensure proper clamping of the tools.
3.9.7 During boring operations, control on feed for finish cut shall be ensured to achieve
required size and finish.
3.10.1 Unless otherwise specified ,the following tolerances can be used for untoleranced
dimensions.
3.11.1 Unless otherwise specified, all completed parts/assemblies shall be cleaned thoroughly
using wire brush or power tools to remove scales, dirts and any other foreign material
before painting.
BHEL QCP:001/05 Page 14 of 16
3.11.2 Where blast cleaning is mentioned before application of special paint, sand or shot blasting
shall be done at area with moisture protected environment. Blasting shall be done with
suitable nozzle with constant velocity and pressure. Compressed air used for blasting
shall be free from moisture. The finished blasted surface shall have metal finish without
any black spots and other foreign matters.
3.11.3 Painting shall be applied within shortest period after blasting is completed.
3.11.4 Any marking about dispatch details shall be as per relevant drawing/SQP. This shall be
painted in bold white paint stenciled letters on the part/assembly.
5.1 All materials shall be handled with properly maintained equipment, tools and tackles to
ensure handling damages. This is applicable at stores , various shops and shipping .
5.2 Ensure capacity of the handling equipment based on the part to be handled.
5.3 Materials/components shall be stored at identified location properly for easy retrieval.
5.5 Storing and preservation of Welding consumables till issue shall be ensured as per
recommendation of WTC. The issue of welding consumables shall be authorized by WTC.
At manufacturing shops the welding consumable are ensured for adequate baking
and drying before use . The issue of welding consumables shall be authorized by shop.
5.7 The assembly shall be securely anchored for dispatch to prevent any damage during
transit. Protrusions from main components shall be suitably protected. All openings shall
be suitably blanked.
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BHEL QCP:001/05 Page 15 of 16
Annexure_I
For Clad plates & Non ASME Materials, refer to the respective Standard / Contract QPs.
BHEL QCP:001/05 Page 16 of 16
ANNEXURE - II
TOLERANCE DRAWINGS
@@@@@@@
BHEL, Tiruchirappalli - 620014. Quality Assurance Standard Inspection Procedure
Product: QUALITY ASSURANCE VISUAL INSPECTION OF PRESSURE PARTS EXCEPT TUBULAR
PRODUCTS ()
------------------------------------------------------------------
Rev. No. Clause No. Details of Revision Remarks
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1.0 SCOPE
This procedure is applicable for visual inspection and
blending of base metal surfaces at welds on drums,
headers, piping and fittings.
This is also applicable for repair of deficient surface
areas on the base materials as well as on welds.
2.0 MATERIALS
All materials of P1, P2, P3, P4 and P5 as per ASME
Section IX and Steel 20 & 12X1MO of GOST specification
will be covered by this procedure.
3.0 SURFACE EXAMINATION BEFORE POST WELD HEAT TREATMENT
Prior to post weld heat treatment, the base metal
surfaces and surfaces at welds in drums, headers,
nozzles, nipples, pipes and fittings shall be visually
examined for surface quality.
The following criteria shall be met:
Base metal surfaces
Minor local surface imperfections noted by visual
examination may be accepted without grinding or weld
repair, provided they are less than 4 mm in depth (2 mm
for fittings). However, the sides shall not be closer
than 2 mm.
In case they don't comply, the depression should be
ground so that the contours comply with the
requirements of 1:4 taper with the adjoining surfaces.
The surface imperfections shall in all cases be free of
tears or cracks. The thickness at the depression shall
not encroach on the minimum design thickness.
Surface at welds
Undercuts shall not exceed 0.8 mm in depth as measured
from the adjacent unaffected surfaces. Areas on pipes or
tubes of diameter 108 mm or less which are used as
nipples shall not contain undercuts that exceed the
lesser of 0.8 mm or 10% of the wall thickness.
Reinforcement requirements
The maximum permitted reinforcement on the butt welds
shall be as follows:
Nominal thickness in mm Maximum reinforcement in mm
circum. jt.| other welds
in pipes & |
Document No.: SIP:PP:02 Rev.No.: 00 Page: 2
tubes |
Upto 3.2 2.4 2.4
over 3.2 to 4.8 incl. 3.2 2.4
over 4.8 to 12.7 incl. 4.0 2.4
over 12.7 to 25.4 incl. 4.8 2.4
over 25.4 to 50.8 incl. 6.35 3.2
over 50.8 to 76.2 incl. * 4.0
over 76.2 to 101.6 incl. * 5.5
over 101.6 to 127 incl. * 6.35
over 127 * 8.0
* The greater of 6.35 or 1/8 times the weld width.
--------------------------------------------------------
4.0 SURFACE EXAMINATION AFTER POST WELD HEAT TREATMENT
When the surface becomes marred after the final postweld
heat treatment, the affected area shall be reconditioned
by grinding and blending to remove all tears and upset
metal. The contour of the ground and blended depression
shall be flared to have a 1:4 taper and to have a
minimum bottom radius of three times the depth.
Such reconditioned areas may be left without weld
repair when they meet the following dimensional limits:
If the depression does not encroach on the required
minimum wall thickness at that region, the length and
width is limited by the requirements on slope of the
flared out area.
If the depression encroaches on minimum wall by not more
than the lesser of 10% of the required minimum wall or
6.4 mm [lesser of 5% or 3.2 mm for fittings] and the
width and the length of the depression do not exceed 50
mm. No two reconditioned areas of this type shall be
closer than 150 mm edge to edge.
When the marred area cannot be reconditioned within the
dimensional requirements given above, the area shall be
repaired by welding in accordance with the
following.
5.0 REPAIR TO WELDS
Parts not meeting the requirements shall be weld
repaired and non-destructively tested as per the origi-
nal requirement. It is the intent that necessary weld
repairs be accomplished prior to heat treatment. It is
mandatory however to meet the requirements listed in the
Cl. 6.0.
When unacceptable indications are detected in weld
joints by visual or by Non destructive examination, the
unacceptable indication shall be removed by mechanical
means or by thermal grooving. When thermal grooving is
used, the excavated area shall be ground as necessary to
assure removal of surface carbides. The excavated areas
shall be free of any irregularities that might trap
slag. These areas shall be magnetic particle examined to
assure complete removal of the defect in case of crack,
lack of fusion or ICP and visually inspected in case of
other defects, and shall then be rewelded.
6.0 REPAIR TO BASE MATERIALS
Document No.: SIP:PP:02 Rev.No.: 00 Page: 3
The welding electrodes, preheat and postweld heat
treatment requirements to base materials shall be in
accordance with the relevant WPS.
The holding time when postweld heat treatment is
required shall be based on the depth of the groove
after preparation for welding.
Weld repairs may be made to "nipple to header/pipe" or
"nipple to drum" weld joints after post weld heat
treatment without subsequent postweld heat treatment
[except for P5 Group 2 & 12X1MO materials], provided the
following conditions are met:
The depth of any rework area ground out shall not exceed
the smaller of 10% of the thickness of the drum/pipe/
header or 50% of the wall thickness of the tube. The
rework shall be limited to P1 (Except SA 106 Gr. C, SA
299 & SA 515 Gr. 70) and P4 materials only if it is on
the drum/header/pipe surface adjacent to the fillet.
The nipples shall not exceed 108 mm in OD except for
P1 material which shall not exceed 150 mm.
The number of rework welds allowed on the base header
material shall not exceed the lesser of 10% of the
nipples on the header or eight (8) rework welds on any
P1 or P4 header. Rework of this type shall be kept to an
absolute minimum by careful examination prior to post-
weld heat treatment.
The number of rework welds on the nipple side for any
single header is not limited.
P4 material need not be postweld heat treated provided
all of the following apply:
1) The outside diameter is 108 mm or less.
2) The wall thickness is 16 mm or less.
3) The specified carbon content is 0.15% or less.
4) A preheat of 125 deg. C or higher is applied.
P5 material need not be postweld heat treated provided
all of the following apply:
1) The outside diameter is 108 mm or less.
2) The wall thickness is 16 mm or less.
3) The specified carbon content is 0.15% or less.
4) A preheat of 150 deg. C or higher is applied.
5) Chromium content does not exceed 3.0%.
Preheat shall be maintained at 150 deg. C minimum from
the time welding is started until the component is given
an extended preheat or an Interstage heat
treatment. This requirement applies to all P5 materials
not exempted by Cl. 6.5 and to SA 106 Gr. C materials
used to fabricate headers.
Extended preheat - Raise preheat in entire weld zone to
300 + 15 deg. C, hold for 4 hours minimum and then cool
to ambient.
Interstage - Heat in furnace to 600 deg. C minimum, but
not to exceed 750 deg. C for half an hour minimum
soaking, and then air or furnace cool to ambient.
Apply a final postweld heat treatment to P5 & SA 106 Gr.
C materials prior to shipment.
Girth Butt welds or repairs to girth butt welds in P1
Document No.: SIP:PP:02 Rev.No.: 00 Page: 4
material (except SA 106 Gr. C), 19 mm or under in thick-
ness need not be post weld heat treated.
7.0 ATTACHMENTS TO PRESSURE PARTS
The welding electrodes, preheat and postweld heat
treatment requirements shall be in accordance with the
relevant WPS.
Wherever required, extended preheat shall be maintained
as per Cl. 6.6.
Post weld heat treatment is not required, if the fillet
weld throat thickness does not exceed 13 mm. For
attachments to P4 and P5 materials, this requirement can
only be applied after all the requirements of clauses
6.4 & 6.5 are met.
Post weld heat treatment is not required after welding
attachments to P1 pressure parts, in situations where
welding after PWHT is unavoidable, provided all of the
following apply:
1) Maximum specified carbon content of the pressure part
does not exceed 0.3%.
2) A minimum preheat of 125 deg. C is applied prior to the
start of welding and is maintained throughout welding.
3) Fillet weld throat thickness does not exceed 13 mm.
4) Pressure part thickness does not exceed 100 mm.
5) An extended preheat of 300 + 15 deg. C is maintained for
4 hours after welding in the case of SA 106 Gr. C
material.
8.0
DOCUMENTATION
8.1
The details of weld repair carried out, if any, shall be
recorded.
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Rev. No. Clause No. Details of Revision Remarks
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1.0 SCOPE
This details out the procedure for welding of lifting
lugs to boiler drums by shielded metal arc welding.
2.0 REFERENCE DOCUMENTS
Engineering Drawings
WPS issued by WTC
3.0 MATERIALS INVOLVED
SA 515 Gr. 70 & SA 299
4.0 PREPARATION PRIOR TO WELDING
Welding of lifting lugs shall be done before final post
weld heat treatment of the drum.
The lug area on the drum surface shall be checked by
straight beam ultrasonic examination for laminations.
The area to be examined shall extend 50 mm beyond the
finished weld for a depth of 50 mm from the surface. Any
defects found exceeding any of the following shall be
repaired.
50% loss of back reflection that extends for more than
25 mm.
Complete loss of back reflection.
Any defects that exceed 600 square cm in any 2400 square
cm area.
The area to be welded shall be chipped, ground or air
arc gouged to a depth of 12 mm in the area of the lug
and 6 mm wider than the lug on each side and at both
ends. Proper preheating shall be carried for air arc
gouging, in case gouging is used for excavating the
area. The gouged area shall be ground to sound metal and
all carbon deposits shall be removed. The ground area
shall be tested by MPI and any defect found shall be
repaired before welding is started (Refer Figure 3).
5.0 FIT-UP AND WELDING
All welding shall be carried out according to the WPS.
The excavated areas shall be first welded and filled up
approximately 1.5 to 3 mm above the surface (Refer
Document No.: SIP:PP:08 Rev.No.: 00 Page: 2
Figure 4). MPI and UT shall be conducted on the weld
after flush grinding.
After welding the excavated areas, the drum may be
allowed to cool before fitting the lugs.
The lugs shall be fitted in position and braced to
prevent an angular distortion of more than 6 mm as the
final alignment tolerance.
After fitting and bracing the lugs, the area to be
welded shall be preheated as per WPS.
Type "A" lugs shall be turned down on the sides for
better welding access (Refer Figure 1).
Type "B" lugs shall be welded wih the lugs turned
straight upon the drum (Refer Figure 2).
After welding from one side, backgouging shall be done
from the other side with necessary preheat. The gouged
area shall be ground and tested by MPI. Then, welding
shall be completed.
After completion of welding, the weld shall be dressed
up and tested by MPI and UT.
6.0 HEAT TREATMENT
The completed drum shall be stress relieved as per the
SQP requirements.
7.0 NDE AFTER HEAT TREATMENT
After HT, the weld shall be tested by MPI and UT.
8.0 DOCUMENTATION
The details of work carried out shall be documented.